Multiple node junction structure

ABSTRACT

Multiple node junctions have at least two nodes sharing an axis. Each node includes a node adaptor-mounting-surface at an angle Θ relative to the axis. An adaptor mounted to each node at the angle Θ relative to the axis uses an adaptor node-mounting-surface and at least one adaptor beam-mounting-surface. A beam having one or more adaptor-mounting-surfaces is mounted to the adaptors using beam adaptor-mounting-surfaces so that the beam is mounted at the angle Θ relative to the axis. The length of each adaptor corresponds to the spacing between each adaptor node-mounting-surface and its matching adaptor beam-mounting-surface. The lengths of the first and second adaptors are selected to accommodate the angle Θ. A framework, for example a free form glass wall or the like, can be created using a plurality of multiple node junctions according to embodiments of the present invention.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority under 35 U.S.C. § 119(e) of the following:

U.S. Provisional Ser. No. 60/742,469 (Attorney Docket No. 1302-p01p) filed on Dec. 05, 2005, entitled MULTIPLE NODE JUNCTION STRUCTURE, the entire disclosure of which is incorporated herein by reference in its entirety for all purposes.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISK APPENDIX

Not applicable.

BACKGROUND

1. Technical Field

This invention relates generally to methods, systems and apparatus for erecting and supporting structures of various types, especially structures using what is commonly referred to as “free form” structures.

2. Description of Related Art

Various techniques and apparatus have been developed for constructing two-dimensional and three-dimensional frameworks and structures that permit free form shapes and configurations. Frequently, wide spanning yet lightweight structures can be assembled for roofs, halls, atria, domes and the like.

Earlier connection systems joined two or more structural members (trusses or beams). All of those connections were realized by means of two node elements. The first node element is connected to the “top” fiber of the member and the second node element is connected to the “bottom” fiber of the member. These arrangements ensured a rigid connection of all structural members connected to each other by means of a minimum of two node elements. Those connections between the structural members could transfer normal forces and shear forces, but also significant bending moments. However, those connection systems had a limited adaptability of the angle between the axis through the two nodes and the longitudinal axis of the structural member (described as angle Θ, below).

Other connection systems are disclosed in U.S. Pat. No. 5,398,475, entitled JOINT-ADAPTER FOR DOUBLY CURVED LATTICE GIRDERS, IN PARTICULAR SINGLE-LAYER TYPES, issued Mar. 21, 1995. These connection systems use a single, hollow node element, typically of cylindrical form. The angle between the node axis and the longitudinal axis of the structural member (that is, angle Θ) can be adapted in a wider range than some earlier systems. However, the transferable bending moment is limited by the relatively small height of the structural member.

Other design systems require special machining of the interconnecting beams (for example, creating stepped or multi-level beam-mounting-surfaces) and various other components. These node connection systems also use one or two node elements. As before, the angle between the node axis and the longitudinal axis of the structural member (angle Θ) can be adapted in a wider range than some earlier systems. However, this range (only 80° to 100°) is too limited for the requirements of modern free-form structures.

Systems, methods and techniques that improve upon earlier design systems and allow more variation and greater angular displacement of support beams, while still maintaining a lightweight structure and overcoming the shortcomings of earlier systems would represent a significant advancement in the art.

BRIEF SUMMARY

Embodiments of the present invention include multiple node junctions having first and second nodes sharing an axis. The first node includes a node adaptor-mounting-surface at an angle Θ relative to the axis. An adaptor mounted to the first node uses an adaptor node-mounting-surface and at least one adaptor beam-mounting-surface. The adaptor node-mounting-surface engages the node adaptor-mounting-surface to mount the adaptor (for example, using a bolt or other mounting means) at the angle Θ relative to the axis. The second node likewise has a node adaptor-mounting-surface at the angle Θ relative to the axis. Similarly, a second adaptor is mounted to the second node and uses an adaptor node-mounting-surface and at least one adaptor beam-mounting-surface. As with the first node's structure, the second adaptor's node-mounting-surface engages the second node's adaptor-mounting-surface to mount the second adaptor at the axis angle Θ.

A beam having one or more generally planar adaptor-mounting-surfaces is mounted (for example, by welding) to the first and second adaptors using the beam adaptor-mounting-surface(s) so that the beam is mounted at the angle Θ relative to the axis. The length of each adaptor corresponds to the spacing between each adaptor node-mounting-surface and its matching adaptor beam-mounting-surface. The lengths of the first and second adaptors are selected to accommodate the angle Θ. A beam extension can be used to accommodate other/further mounting surfaces. A framework, for example a free form glass wall or the like, can be created using a plurality of multiple node junctions according to embodiments of the present invention.

Further details and advantages of the invention are provided in the following Detailed Description and the associated Figures.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which:

FIG. 1 is an isometric top view of one embodiment of the present invention may be used.

FIG. 2 is an isometric bottom view of one embodiment of the present invention may be used.

FIG. 3 is a top view of one embodiment of the present invention may be used.

FIG. 4A is a cross-sectional view of the structure of FIG. 3 along the line A-A of FIG. 3.

FIG. 4B is another cross-sectional view of one embodiment of the present invention.

FIG. 5 is a top view of a node blank usable in connection with embodiments of the present invention.

FIG. 6 is a cross-sectional view of the node blank of FIG. 5 along the line A-A of FIG. 5.

FIG. 7 is a top view of a node usable with embodiments of the present invention.

FIG. 8 is a cross-sectional view of the node of FIG. 7 along the line A-A of FIG. 7.

FIG. 9 is an isometric view of the node of FIG. 7 along the arrow A of FIG. 8.

FIG. 10 is a perspective view of an adaptor usable with embodiments of the present invention.

FIG. 11 is another perspective view of an adaptor usable with embodiments of the present invention.

FIG. 12 is a top view of an adaptor usable with embodiments of the present invention.

FIG. 13 is a side cross-sectional view of an adaptor usable with embodiments of the present invention.

FIG. 14 is a perspective view of a beam usable with embodiments of the present invention.

FIG. 15 is a side view of a beam usable with embodiments of the present invention.

FIG. 16 is a detailed side view of a beam usable with embodiments of the present invention.

FIG. 17 is a detailed top view of a beam usable with embodiments of the present invention.

FIG. 18 is a perspective view of a frame constructed according to one or more embodiments of the present invention.

DETAILED DESCRIPTION

The following detailed description of the invention will refer to one or more embodiments of the invention, but is not limited to such embodiments. Rather, the detailed description is intended only to be illustrative. Those skilled in the art will readily appreciate that the detailed description given herein with respect to the Figures is provided for explanatory purposes as the invention extends beyond these limited embodiments.

As described in more detail below, a multiple node support structure uses two or more nodes at the junction of two or more beams mounted thereto for supporting various structures. The multiple node junction structure uses node-mounting-surfaces and adaptors to permit beams connected to a junction to be mounted at various angles relative to one another and/or the nodes. The result is a support structure that is relatively lightweight and flexible, yet extremely strong and durable. It is usable in a variety of settings, including free form structures that require dramatic changes in support structure orientation with minimal structural intrusion into the design.

More specifically, a number of improvements can be realized using embodiments of the present invention. The angle between the node axis and the longitudinal axis of the structural member (that is, angle Θ) can be adapted to a much greater range. No machining of the node cavity is required. The stepped beam ends and corresponding differences in adaptor lengths require only minimal machining of connection faces at the nodes. However, no handling of the whole beam for machining operations is required because the adaptors can be produced very accurately and are then only welded to the beam ends.

One embodiment of the multiple node junction structure 100 of the present invention is shown in FIGS. 1-4B. A first node 110 and a second node 120, typically (though not necessarily) oriented as an “upper” node and a “lower” node, respectively, are spaced apart to create a node set or junction 105. Nodes 110, 120 share an axis 130. In some embodiments, the nodes are generally circular, cylindrical and/or toroidal and axis 130 passes through the center of each node. As will be appreciated by those skilled in the art, each node can be generally hollow when toroidal in shape or can be more solid, depending on the needed strength for a given structure. Each node has one or more adaptor-mounting-surfaces 114 (also seen as surfaces 714 in FIGS. 7-9) that is oriented at an angle Θ relative to axis 130. Using embodiments of the present invention, the angle Θ can vary from about 60° to 120°, including 90°, where the adaptor-mounting-surface of a node is parallel to axis 130. The nodes 110, 120 can be tapped with holes 112, if appropriate, as seen in FIG. 3 (also seen as holes 712 in FIGS. 7-9).

Nodes 110, 120 and the like can be created using a standard blank, as shown in FIGS. 5 and 6. A toroidal blank 510 has a primary center bore 512 and secondary upper and lower bores 514 that make fabrication relatively easy and inexpensive. The outer cylindrical face of blank 510 can be machined to create adaptor-mounting-surfaces at desired angles and positions for a given structure. Moreover, as noted above, blanks 510 can be tapped to provide threaded holes for bolts or other mounting means that allow nodes to be mounted to adaptors as desired, as will be appreciated by those skilled in the art. Again, the taps may be drilled and threaded at desired angles and positions to permit customization of each node for a given free form or other structure. Blanks are processed to generate nodes such as the node 710 shown in FIGS. 7-9. Node 710 has a plurality of tapped holes 712 penetrating adaptor-mounting-surfaces 714. Holes 712 and mounting surfaces 714 can be uniformly distributed around the periphery of the node 710 or can be sited at irregular intervals, as needed. Moreover, the adaptor-mounting-surfaces 714 can be uniform in their angular displacement Θ from the axis 720 of the node 710 or can have different angular displacements, again as needed.

As seen in FIGS. 1-4B, beams 140 are mounted to nodes 110, 120 using adaptors 150. The beams 140 can provide support structure for glass or other building materials, as appropriate. The adaptors 150 provide a simplified way of mounting the beams 140 to the nodes 110, 120. In some embodiments of the present invention, the adaptors 150 are welded to the beams 140 and any beam extensions 144 used as well.

As seen in more detail in FIGS. 10-13, each adaptor 850 has a node-mounting-surface 852 that engages an adaptor-mounting-surface on a node when the structure is assembled. This engagement between a node-mounting-surface and an adaptor-mounting-surface means that an adaptor's longitudinal axis (which is parallel to the longitudinal axis of a beam mounted to adaptor) will be oriented at the angle Θ relative to the axis 130 also. Each adaptor 850 also has at least one beam-mounting-surface 854 that permits the adaptor 850 to be mounted to a beam by any appropriate means, such as welding or the like. In some embodiments of the present invention, multiple beam-mounting-surfaces can be found on an adaptor. For example, in FIGS. 1-4B, each adaptor 150 has two beam-mounting-surfaces. Shown in more detail in FIGS. 10-13, one beam-mounting-surface 854 is generally parallel to the node-mounting-surface 852 and the other beam-mounting-surface 856 is perpendicular to the node-mounting-surface 852. Each adaptor 850 can include a cavity 858 that provides ready access to a mounting means for mounting the adaptor to a node. In some embodiments of the present invention, such as those shown in FIGS. 1-4B and 10-13, the mounting means is a bolt 860 that can be threaded through an access hole 857 in the adaptor 850 to engage a tapped hole in a node. Other methods and configurations for mounting adaptors to beams and for mounting adaptors to nodes will be apparent to those skilled in the art.

Specific mountings of adaptors to beams are shown in FIGS. 14-17. A beam 910 can have multiple adaptors 950 mounted to it, as seen in FIG. 14. The beams can be made of any suitable material, which may depend on the structure and its weight and load-bearing demands, as will be appreciated by those skilled in the art. Steel and other materials are commonly used and others are known to those skilled in the art. In FIGS. 14 and 15, each adaptor 950 has been welded to beam 910 using two attachment surfaces. One is an end surface such as surface 854 of FIG. 10. A “bottom” surface of an adaptor, such as surface 856 of FIG. 13 also can be used. The adaptor's end surface can be welded to a planar end 912 of the beam 910 in FIGS. 15 and 16. As will be described in more detail below, these planar ends of the beam 910 do not require special multiple level machining to accommodate adaptor pairs, which provides significant advantages over earlier structures that utilized stepped or otherwise specialized beam end configurations. The adaptors' bottom surfaces are welded to a beam extension 914 that is welded to the end 912 of beam 910, as seen in more detail in FIGS. 16 and 17. Other mounting schemes for the adaptors and beams will be apparent to those skilled in the art. The adaptors typically are mounted with access cavities 958 facing “up” or “down” to facilitate access to bolts or other mounting means during assembly. Of course other mounting means access configurations are available (for example, “side” access cavities, rivets, etc.) and will not be described in detail herein.

As seen in FIGS. 14-16, adaptors mounted to the same end of a beam 910 may be of different lengths. For example, in FIGS. 15 and 16 adaptor 950 a is longer than adaptor 950 b. Because adaptors 950 are standardized as to shape and function, they can be easily adjusted as to length by simply cutting some adaptors shorter than others, as needed. This simple length adjustment to an adaptor pair on one end of a beam (that is, differential between adaptors in a given adaptor pair) provides dramatic angular flexibility without special or complicated processing of the beam and/or nodes involved. As explained in more detail below, this easy variability in adaptor length provides excellent adaptability of embodiments of the present invention for use in various structural settings and uses.

Mounting of beams to nodes is shown in detail in FIGS. 1-4B. Specifically in FIGS. 3, 4A and 4B, a plurality of beams 140 are mounted to nodes 110, 120. As will be appreciated by those skilled in the art, more than 2 nodes could be used in each node set, wherein an adaptor 150 would be provided for each such node and a single beam would use as many adaptors 150 as necessary to effectuate proper mounting to a given node set. In FIGS. 3 and 4A, bolts 180 are used as mounting means to mount adaptors 150 to nodes 110, 120. Each adaptor-mounting-surface 114 engages a node-mounting-surface 152 to mount a given adaptor 150 at an angle Θ relative to axis 130, as noted above. Again, adaptors 150 can be mounted to beams 140 in any suitable manner, for example by welding.

In FIGS. 4A and 4B adaptor 150 b is longer than adaptor 150 a. Adaptor 150 b is longer to accommodate the angle Θ at which beam 140 is being mounted relative to axis 130. This configuration requires providing adaptors of different lengths, but allows uniform node structure relative to node 110 and node 120 and allows the adaptor-mounting-surface of beam 140 to be simply planar, thus reducing the machining needed for individual beams 140 in the structure. Instead, relatively minor adjustments can be made to the lengths of adaptors to accommodate the various values of Θ provided in a structure (sometimes multiple values of Θ in a single junction or node set).

As shown in more detail in FIG. 4B, the needed length difference for adaptors 150 a and 150 b can be calculated using simple trigonometric functions/equations, as will be appreciated by those skilled in the art. As shown in FIG. 4B, the length difference Δ for the adaptors can be calculated as Δ=(H−h)*tan(Θ−90°). When Θ is less than 90°, then adaptor 150 a will be shorter than adaptor 150 b. When Θ is greater 90°, then adaptor 150 a will be longer than adaptor 150 b. Finally, when Θ is 90° exactly, adaptors 150 a, 150 b will be the same length. A frame or grid 1810 of multiple node structures is shown in FIG. 18. Each junction 1820 on the frame 1810 consists of two or more nodes 1830 in a node set mounted to two or more beams 1840. This type of structure allows free form construction and mounting of glass and/or other materials with a minimum of intrusion by the support structure.

The many features and advantages of the present invention are apparent from the written description, and thus, the appended claims are intended to cover all such features and advantages of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, the present invention is not limited to the exact construction and operation as illustrated and described. Therefore, the described embodiments should be taken as illustrative and not restrictive, and the invention should not be limited to the details given herein but should be defined by the following claims and their full scope of equivalents, whether foreseeable or unforeseeable now or in the future. 

1. A multiple node junction comprising: a first node and a second node, wherein the first and second nodes share an axis; the first node comprising a first node adaptor-mounting-surface, wherein the first node adaptor-mounting-surface is at an angle Θ relative to the axis; a first adaptor mounted to the first node, the first adaptor comprising: a first adaptor node-mounting-surface; and a first adaptor beam-mounting-surface; wherein the first adaptor node-mounting-surface engages the first node adaptor-mounting-surface to mount the first adaptor at the angle Θ relative to the axis; the second node comprising a second node adaptor-mounting-surface, wherein the second node adaptor-mounting-surface is at the angle Θ relative to the axis; a second adaptor mounted to the second node, the second adaptor comprising: a second adaptor node-mounting-surface; and a second adaptor beam-mounting-surface; wherein the second adaptor node-mounting-surface engages the second node adaptor-mounting-surface to mount the second adaptor at the angle Θ relative to the axis; a beam having a generally planar adaptor-mounting-surface, wherein the first adaptor and the second adaptor are mounted to the beam adaptor-mounting-surface so that the beam is mounted at the angle Θ relative to the axis; further wherein the length of the first adaptor corresponds to the spacing between the first adaptor node-mounting-surface and the first adaptor beam-mounting-surface; and further wherein the length of the second adaptor corresponds to the spacing-between the second adaptor node-mounting-surface and the second adaptor beam-mounting-surface; further wherein the first adaptor length and the second adaptor length are selected to accommodate the angle Θ.
 2. The multiple node junction of claim 1 wherein the beam further comprises a beam extension mounted to the beam adaptor-mounting-surface, wherein the beam extension comprises a first beam extension adaptor-mounting-surface and a second beam extension adaptor-mounting-surface; further wherein the first adaptor further comprises a first adaptor extension mounting surface mounted to the first beam extension adaptor-mounting-surface; and further wherein the second adaptor further comprises a second adaptor extension mounting surface mounted to the second beam extension adaptor-mounting-surface.
 3. The multiple node junction of claim 1 wherein the first and second adaptors are welded to the beam.
 4. The multiple node junction of claim 1 wherein the first node comprises a plurality of adaptor-mounting-surfaces and further wherein the second node comprises a plurality of adaptor-mounting-surfaces corresponding to the first node plurality of mounting surfaces.
 5. The multiple node junction of claim 1 wherein the first adaptor is mounted to the first node adaptor-mounting-surface using a bolt; and further wherein the second adaptor is mounted to the second node adaptor-mounting-surface using a bolt.
 6. The multiple node junction of claim 1 wherein each adaptor comprises a cavity for accessing means for mounting the adaptor to one of the nodes.
 7. The multiple node junction of claim 1 wherein Θ is from about 60° to about 120°.
 8. The multiple node junction of claim 1 wherein each node is generally toroidal in shape and has a tapped hole for each adaptor mounted to the node.
 9. A framework comprising a plurality of multiple node junctions, wherein each multiple node junction comprises: a first node and a second node, wherein the first and second nodes share an axis; the first node comprising a first node adaptor-mounting-surface, wherein the first node adaptor-mounting-surface is at an angle Θ relative to the axis; a first adaptor mounted to the first node, the first adaptor comprising: a first adaptor node-mounting-surface; and a first adaptor beam-mounting-surface; wherein the first adaptor node-mounting-surface engages the first node adaptor-mounting-surface to mount the first adaptor at the angle Θ relative to the axis; the second node comprising a second node adaptor-mounting-surface, wherein the second node adaptor-mounting-surface is at the angle Θ relative to the axis; a second adaptor mounted to the second node, the second adaptor comprising: a second adaptor node-mounting-surface; and a second adaptor beam-mounting-surface; wherein the second adaptor node-mounting-surface engages the second node adaptor-mounting-surface to mount the second adaptor at the angle Θ relative to the axis; a beam having a generally planar adaptor-mounting-surface, wherein the first adaptor and the second adaptor are mounted to the beam adaptor-mounting-surface so that the beam is mounted at the angle Θ relative to the axis; further wherein the length of the first adaptor corresponds to the spacing between the first adaptor node-mounting-surface and the first adaptor beam-mounting-surface; and further wherein the length of the second adaptor corresponds to the spacing between the second adaptor node-mounting-surface and the second adaptor beam-mounting-surface; further wherein the first adaptor length and the second adaptor length are selected to accommodate the angle Θ. 